Bearing and coupler-journal devices for panels

ABSTRACT

A journal-coupler includes a first portion including a first pair of flanges and a first coupler portion and a second portion that is removably connected to the first portion. The second portion includes a second pair of flanges and a second coupler portion. The first coupler portion and the second coupler portion combine to form an enclosed torque tube portion.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the priority benefit of U.S. Provisional PatentApplication Ser. No. 62/647,778, filed Mar. 25, 2018 and 62/648,546,filed on Mar. 27, 2018, which are both incorporated herein by referencein their entirety.

TECHNICAL FIELD

One or more embodiments relate generally to devices for rotationalpanels, and in particular, bearing and coupler-journal devices forsupporting rotational panels.

BACKGROUND

Single axis trackers are mounting structures used for the controlledmovement of photovoltaic solar panels and other solar collecting meansfrom east to west to track the sun daily.

SUMMARY

Some embodiments provide bearing and coupler journal devices forsupporting rotational panels. One embodiment includes a journal-couplerthat includes a first portion including a first pair of flanges and afirst coupler portion and a second portion that is removably connectedto the first portion. The second portion includes a second pair offlanges and a second coupler portion. The first coupler portion and thesecond coupler portion combine to form an enclosed torque tube portion.

These and other features, aspects and advantages of the one or moreembodiments will become understood with reference to the followingdescription, appended claims, and accompanying figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a first portion of a coupler-journal, according to someembodiments;

FIG. 1B shows a second portion of a coupler-journal, according to someembodiments;

FIG. 2 shows a coupler-journal including the first portion (FIG. 1A) andthe second portion (FIG. 1B), according to some embodiments;

FIG. 3A shows a front view of the first portion of the coupler-journalbeing placed into a lower bearing portion, according to someembodiments;

FIG. 3B shows a side view of the first portion of the coupler-journalbeing placed into the lower bearing portion, according to someembodiments;

FIG. 4 shows a perspective view of the first portion of thecoupler-journal placement into the lower bearing portion, according tosome embodiments;

FIG. 5A shows a top view of the first portion of the coupler-journalcoupled with the lower bearing portion, according to some embodiments;

FIG. 5B shows a front view of the first portion of the coupler-journalcoupled with the lower bearing portion, according to some embodiments;

FIG. 5C shows a side view of the first portion of the coupler-journalcoupled with the lower bearing portion, according to some embodiments;

FIG. 6 shows a perspective view of the first portion of thecoupler-journal coupled with the lower bearing portion, according tosome embodiments;

FIG. 7A shows a front view of torque tubes being placed into the firstportion of the coupler-journal that is connected with the lower bearingportion, according to some embodiments;

FIG. 7B shows a side view of torque tubes being placed into the firstportion of the coupler-journal that is connected with the lower bearingportion, according to some embodiments;

FIG. 8A shows a front view of torque tubes placed within the firstportion of the coupler-journal that is connected with the lower bearingportion, according to some embodiments;

FIG. 8B shows a side view of the torque tubes placed within the firstportion of the coupler-journal that is connected with the lower bearingportion, according to some embodiments;

FIG. 9A shows a front view of the second portion of the coupler-journalbeing placed over torque tubes that are placed within the first portionof the coupler-journal that is connected with the lower bearing portion,according to some embodiments;

FIG. 9B shows a side view of the second portion of the coupler-journalbeing placed over torque tubes that are placed within the first portionof the coupler-journal that is connected with the lower bearing portion,according to some embodiments;

FIG. 10A shows a front view of the second portion of the coupler-journalsecurely connected with the first portion of the coupler-journal withthe torque tubes placed between the first portion and the second portionof the coupler-journal, and the first portion of the journal-coupler isconnected with the lower bearing portion, according to some embodiments;

FIG. 10B shows a side view of the second portion of the coupler-journalsecurely connected with the first portion of the coupler-journal withthe torque tubes placed between the first portion and the second portionof the coupler-journal, and the first portion of the journal-coupler isconnected with the lower bearing portion, according to some embodiments;

FIG. 11A shows a front view of an upper bearing portion being placedover the second portion of the coupler-journal that is securelyconnected with the first portion of the coupler-journal with the torquetubes placed between the first portion and the second portion of thecoupler-journal, and the first portion of the journal-coupler isconnected with the lower bearing portion, according to some embodiments;

FIG. 11B shows a side view of an upper bearing portion being placed overthe second portion of the coupler-journal that is securely connectedwith the first portion of the coupler-journal with the torque tubesplaced between the first portion and the second portion of thecoupler-journal, and the first portion of the journal-coupler isconnected with the lower bearing portion, according to some embodiments;

FIG. 12A shows a front view of an upper bearing portion securelyconnected to the bottom bearing portion, where the second portion of thecoupler-journal is securely connected with the first portion of thecoupler-journal with the torque tubes placed between the first portionand the second portion of the coupler-journal, and the first portion ofthe journal-coupler is connected with the lower bearing portion,according to some embodiments;

FIG. 12B shows a side view of an upper bearing portion securelyconnected to the bottom bearing portion, where the second portion of thecoupler-journal is securely connected with the first portion of thecoupler-journal with the torque tubes placed between the first portionand the second portion of the coupler-journal, and the first portion ofthe journal-coupler is connected with the lower bearing portion,according to some embodiments;

FIG. 13 shows a perspective isolated view of the lower bearing portion,according to some embodiments;

FIG. 14A shows a front perspective isolated view of the upper bearingportion, according to some embodiments;

FIG. 14B shows a rear perspective isolated view of the upper bearingportion, according to some embodiments;

FIG. 15 shows a combined perspective view of the upper bearing portionand the lower bearing portion, according to some embodiments; and

FIG. 16 shows a perspective view of the coupler-journal coupled with theupper bearing portion securely connected to the lower bearing portionthat is connected to a pier, according to some embodiments.

DETAILED DESCRIPTION

The following description is made for the purpose of illustrating thegeneral principles of one or more embodiments and is not meant to limitthe inventive concepts claimed herein. Further, particular featuresdescribed herein can be used in combination with other describedfeatures in each of the various possible combinations and permutations.Unless otherwise specifically defined herein, all terms are to be giventheir broadest possible interpretation including meanings implied fromthe specification as well as meanings understood by those skilled in theart and/or as defined in dictionaries, treatises, etc.

One or more embodiments relate generally to devices for rotationalpanels, and in particular, bearing and coupler-journal devices forsupporting rotational torque tubes for solar panels. One embodimentprovides a journal-coupler that includes a first portion including afirst pair of flanges and a first coupler portion and a second portionthat is removably connected to the first portion. The second portionincludes a second pair of flanges and a second coupler portion. Thefirst coupler portion and the second coupler portion combine to form anenclosed torque tube portion.

Some embodiments are directed to an apparatus that is both a mechanicalcoupler and a rotating journal. In one embodiment, the device includestwo halves that connect together (e.g., via bolts, fasteners, welding,etc.), clamping around multi-sided torque tube axles (e.g., buttedend-to-end, or closely end-to-end, etc.), and connecting the torquetubes together and transferring the axial torque from one torque tube tothe next. In one embodiment, the outside surface of the central bodyforms a cylindrical journal that turns inside a bearing (e.g., a round,circular, multifaceted, etc.) surface, establishing a bearing for therotating torque tubes. In one example embodiment the metal-to-metal,round-to-round interface between the electrically conductive device andthe electrically conductive bearing establishes a continuous groundpath. The three functions of coupling together two torque tubes,performing as a journal in a bearing, and providing an electrical groundpath are necessary for single axis tracking systems used on solarphotovoltaic power plants.

It should be noted that most conventional single axis trackers utilize acoupling mechanism to connect many load-carrying axle segments or torquetubes end-to-end to form an axle on which solar panels are mounted androtated to track the sun in a single axis direction. All single axistrackers must have each of their electrically conductive partselectrically grounded to earth ground. The torque tube system is themain grounding trunk for collecting the ground from the metal frames ofthe attached solar panels, the solar panel mounting hardware, and themounting posts or piers. Plastic bushings typically used within thebearing system electrically isolate the posts or piers from the torquetubes, necessitating a flexible grounding strap from each and everynon-moving post or pier to the grounded, rotating torque tube system.

Conventional systems use conventional bearings, couplers, and groundingstraps independently, constituting three distinct parts. Mostconventional trackers utilize a torque tube coupling system forconnecting torque tubes end-to-end that is separate and independent fromthe bearing, located a distance away. This constitutes two distinctparts of the coupler and the bearing to perform two distinct functions.Some conventional systems use a shaft journal with a flange at each ofthe two ends of the shaft, each flange having a bolt hole pattern toconnect a torque tube on either end, which also have similar flanges.This design adjoins two adjacent torque tubes to complete the torquetube axle system. This design, while utilizing a single part to performthe two functions of a simple bearing journal and a torque tube coupler,requires the addition of mating flanges onto the ends of the torquetubes.

Most conventional systems include a plastic sleeve as a bushing betweenthe journal and the bearing to prevent metal-to-metal rubbing and thusincrease the number of parts. The plastic bushing is electricallynon-conductive and electrically isolates the metallic journal from themetallic bearing for preventing a ground path from each post to thetorque tube and thus, requiring a separate, field applied, flexibleground wire between the post and the rotating, grounded torque tube(increasing the parts count). This ground strap must flex and surviveapproximately 22,000 flexes from the daily east to west rotation over atypical thirty year life span of a solar utility plant. This addedground wire at each and every post requires terminal studs to beattached, usually by field welding, to the posts and to the torque tubesat each post location, to function as terminals onto which the groundwires are to be attached. Note that the fabrication of the ground wire,the field welding attachment of the two studs at each and every postlocation, the cleaning of the weld-induced burned galvanization followedup with an application of zinc rich paint, followed by torque wrenchtightening of the two ring terminals of the ground wire to the two studsincorporates much labor and much human and field condition variabilitythat brings into question consistency, quality, durability, andreliability of those ground paths.

Plastic bushings or plastic wear surfaces placed in between the turningjournal and the stationary bearing are assumed to be required because ofvarious fears about a metal-on-metal simple bearing. Some of these fearsare that: there will be much friction requiring much turning torque; thesystem will squeak or make noise when turning; the metal interface willrust once the galvanization is worn away; and the rubbing metalcomponents will wear thin and eventually fail mechanically. Note thatsquare torque tubes used as couplers have been used as the journalinside a round simple bearing. The two relatively small surface areas ofthe two bottom corners of the square torque tube suffer from excessivewear caused by their excessive surface pressure during rotation. Theprimary reason for plastic bushings is to distribute the weight, andhence pressure, away from the small area of the two corners of a squaretorque tube to the much broader area of the round surface area typicalin a round bearing system. One disadvantage of the plastic bushing isthat they can break, especially if deployed improperly. Plastic can makea strong and durable wear surface but does not work well as a structuralelement used as a moving part that must withstand cyclic stress, such aswould be the case of a rotating plastic bushing in a simple bearingsystem on a single axis tracker that must withstand an approximate22,000 cycles of cyclic stress resulting from the shifting weight of thetracking solar panels, from various wind events, and from decades ofthermal expansion and contraction of the long torque tube axle.

Many of the conventional single axis tracker systems have bushings andjournals that must be placed onto the torque tube prior to fieldassembly. For example, a fully round journal, a fully round bushing, anda fully round bearing can only be installed from the ends of the torquetube and therefore must be slid onto the torque tubes before the torquetubes are coupled together. Sometimes, if the workers are not 100%careful, a bushing or journal can be inadvertently turned by one facetof the torque tube and the error is not discovered until the system isready for commissioning, at which point the entire assembly around thaterror must be disassembled in order to correct the error, which involvessliding the components off the end of the torque tube, rotating thecomponent in correct alignment, and then sliding the components back onto the torque tube.

Some conventional single axis trackers utilize a one piece bearingcomponent, and some single axis trackers utilize two bearing components,a bottom and a top, that are bolted together and by which the boltprovides all the holding strength to keep the top bearing componentaffixed to the bottom bearing component when a force is placed on thetop bearing component (as a result of angular rotation of the solarpanels or an upward wind force placed onto the solar panels, both ofwhich place a force on the torque tube and journal that turns inside thebearing).

Some embodiments provide steel-on-steel friction that is relatively low,especially after the rubbing surfaces become shiny smooth over time.Movement is silent because the rotation is slow, is limited toapproximately 90 degrees of rotation throughout the daylight hours, andis infrequent as it turns and stops in small increments. The metalinterface is effectively wiped twice a day, keeping both surfaces ofbearing and journal rust free, shiny, smooth, and electricallyconductive. In some embodiments, the large surface area of thecylindrical journal against the large cylindrical bearing surfaceminimizes the interface pressure and minimizes the wear. The wallthicknesses of the journal and the bearing are both sufficiently thickto survive and function structurally for the life of the system.

Some embodiments provide advantages over the conventional systems andcomponents, such as: (a) providing a clamp-on coupler for the torquetubes of a single axis tracker that also performs the function of around journal in a simple bearing for the turning torque tubes; (b)providing a clamp-on journal for a single axis tracker that provides athick, round gliding interface that maximizes the surface area to thesimple bearing; (c) providing a method of electrically grounding thesimple bearing, and hence the post on which it is firmly attached, tothe journal and hence to the torque tube that is clamped together withthe coupler-journal, accomplished principally by the relatively largemetal-to-metal contact surface areas of the cylindrical journal and theround bearing; (d) providing a coupling method that doubles as a journalthat adjusts without having to be slid off of, and back on to, thetorque tube from the ends of the torque tubes, which simplifiesadjustment, rework, and replacement; (e) providing a clamp-on journalthat can be used on a single torque tube to function solely as a journalin a simple bearing to support that torque tube; (f) providing aclamp-on journal that can be used on a single torque tube to functionsolely as a ground path for that torque tube; and (g) providing anintegral grounding path and method without having to add any additionalhardware such as a ground strap or a ground wire and attachment devicesfor a ground strap or ground wire.

One or more embodiments have a configuration of metal-on-metal simplebearing that: has a relatively low coefficient of friction between steeland steel; does not squeak because the rotation is very slow andinfrequent; will not rust at the simple bearing interfaces because saidinterface is automatically/dynamically wiped clean daily during movementand maintains a shiny, rust-free surface; will not wear out and failwithin the approximate thirty-year life for at least three reasons: (a)the surface contact area is sufficiently large so as to significantlyreduce the contact pressure and significantly reduce the rate of wear;(b) the turning action happens only about 22,000 times over the courseof a thirty-year operational life; and (c) the thicknesses of thejournal and of the simple bearing are sufficient enough to have therequired structural strength over the intended life of the system.

It should be noted that low prices for renewable energy mandate thatcost savings be achieved in the material cost, the installation cost,and the operation and maintenance (O&M) cost. Material costs can be andare reduced by having fewer parts, which can be achieved by having onepart to perform multiple functions. Therefore, some embodiments includea coupler-journal that performs as a coupler to hold together twoadjacent torque tubes end-to-end and also performs as a journal in asimple bearing system to allow the torque tubes to rotate. Materialcosts can also be reduced by removing the need for a separate groundstrap at each and every post via the effective electrical groundcommutation process of the simple bearing system.

Installation costs can be and are reduced by having fewer parts toinstall, such as combining a coupler and a journal into one part.Further reductions in installation labor can be realized by not havingto apply a ground strap in the field at each and every post of whichmust electrically connect the stationary post to the rotating torquetube. O&M costs are reduced by having fewer parts to inspect, maintain,repair, or replace. In some embodiments, this cost is further reduced byhaving a bolt together system that can be unbolted for easy adjustmentor replacement in the field.

Some embodiments include a specialized coupler that performs also as ajournal in a simple bearing system, and if all system parts areelectrically conductive then the system also performs as a continuousground path. One or more embodiments provide: a coupler to join twotorque tubes end-to-end; a journal coincident with the coupler thatturns inside a simple bearing and that does not require a bushing; and ajournal in a simple bearing system that maintains a continuous groundpath. In one example embodiment, the same coupler that connects twotorque tubes end-to-end via clamping also performs as a journal in asimple bearing system via its smooth, cylindrical outer surface, withenough surface area to minimize pressure and wear; and with enoughconstant, conductive contact area to also perform as an integral groundpath. In some embodiments, the length of each torque tube is the same asthe distance between the supporting posts such that two adjacent torquetubes butt-up against each other centrally over the coupler, whichprovides the coupler to also serve as a journal centered in a bearing.In one or more embodiments, there are no intermediary bushing ofplastic, metal or any other material. In some embodiments, a metaljournal turns inside a metal bearing to form a simple bearing. Themetal-on-metal contact between the two (e.g., circular) surfaces, aidedby the weight of the torque tubes and the weight of solar panelssupported by the torque tubes, creates a constant ground path betweenthe journal and the bearing. In one or more embodiments, the outerjournal surface of the coupler-journal is cylindrical so as to givemaximum surface area of contact to the circular bearing surface, thusminimizing the pressure on both interfacing surfaces of thecoupler-journal and the bearing. In one or more embodiments, thecoupler's inner surface may be faceted in the same shape and approximatedimensions of the multi-sided torque tube, therefore capable of clampingthe two butting torque tubes together and transferring the torque fromone torque tube to the adjoining torque tube while keeping the abuttingtorque tubes in axial and rotational alignment. In some embodiments, thecoupler's inner surface is non-faceted in the same non-faceted shape andapproximate dimensions of a round torque tube, therefore being capableof clamping the two abutting torque tubes together and transferring thetorque from one torque tube to the adjoining torque tube while keepingthe abutting torque tubes in axial and rotational alignment. Thethickness of the material between the outer round surface of the journaland the inner faceted or non-faceted surface of the coupler is ofsufficient to transfer the calculated torque from one torque tube to thenext for the life of the tracker system while taking into accountlifetime wear.

FIG. 1A shows a first portion 110 of a coupler-journal, according tosome embodiments. FIG. 1B shows a second portion 120 of acoupler-journal, according to some embodiments. In some embodiments, thefirst portion 110 and the second portion 120 are two identicalcoupler-journal halves, each including a half central body (e.g.,cylindrically shaped, multi-faceted shaped, etc.) with two flanges, oneon each side of the central body. In one or more embodiments, the firstportion 110 includes a first opening (or cutout, window, etc.) 111 and asecond opening (or cutout, window, etc.) 112; and the second portion 120includes a third opening (or cutout, window, etc.) 121 and a fourthopening (or cutout, window, etc.) 122. The first portion 110 includesthrough-holes (or fastening openings) 113; and the second portion 120includes through-holes (or fastening openings) 123. The first portion110 includes a torque tube 720 (see, e.g., FIG. 7) cradle or couplerportion 114; and the second portion 120 includes a torque tube 720cradle or coupler portion 124.

In some embodiments, when the first portion 110 and the second portion120 are fixed together (e.g., using nuts and bolts, bolts, machinescrews, any other fastening devices or techniques) they form a completecoupler-journal unit (see, e.g., FIG. 2). Each side of the first portion110 and the second portion 120 form a flange that each has a centralizedcutout (first opening 111, second opening 112, third opening 121, fourthopening 122) close to the central body to avoid interference with thebearing. The flanges have the through-holes 113/123 for couplingtogether the two coupler-journal halves (first portion 110 and thesecond portion 120). In one or more embodiments, the body of each of thefirst portion 110 and the second portion 120 coupler-journal halvesforms a half “cylinder,” where the outside surface, or a central portionof the outside surface, is rounded and smooth to function as the roundjournal surface, which rests and turns inside a bearing. In someembodiments, the interior surface of the central body of the firstportion 110 and the second portion 120 coupler-journal halves is facetedin the same approximate size and form to snuggly mate against half of amulti-sided torque tube 720 or two adjoining multi-sided torque tubes720.

In one or more embodiments, the first portion 110 and the second portion120 are made of a metal, a metal alloy, an electrically conductiveplastic, etc. In some embodiments, the first portion 110 and the secondportion 120 may be sized and have a particular thickness according tothe diameter and sizing of torque tube 720 that is required for aparticular sized solar panel.

FIG. 2 shows a coupler-journal including the first portion 110 (FIG. 1A)and the second portion 120 (FIG. 1B), according to some embodiments. Inone example embodiment, the first portion 110 and the second portion 120are fixed together with fasteners 210 (e.g., bolts, nut and bolts,screws, etc.) and form combined windows 221 and 222, and the enclosedportion 223 for a torque tube 720 (FIG. 7). In some embodiments, thecoupler-journal formed by the first portion 110 and the second portion120 performs multiple functions such as: a coupler for connecting twotorque tubes 720 end-to-end, a coupler-journal that rotates in a simplebearing system, and an electrical path for electrical grounding betweenthe coupler-journal and a bearing formed by lower bearing portion 310and upper bearing portion 315 (see, e.g., FIGS. 11A-B, 12A-B, 13, 14A-B,15 and 16).

In some embodiments, continuous contact, pressure, and wiping back andforth between the outer journal-coupler surface (outer surface of firstportion 110 and second portion 120) and the interior surface of thelower bearing portion 310 and the upper bearing portion 315 that form asimple bearing, sustains a continuous electrical ground path between thejournal-coupler, the torque tubes 720 (FIG. 7) and the bearing formed bythe lower bearing portion 310 and the upper bearing portion 315.

In one or more embodiments, the combined windows 221 and 222 providecutout clearance for turning the journal-coupler within the bearing. Theflanges of the first portion 110 and the second portion 120 alsofunction as physical stops at the two extreme rotational limits of theturning torque tube, and thus may be sized according to the requiredrotational angle limits.

In some embodiments, for each coupler-journal half (the first portion110 and the second portion 120) the body is the approximate shape of ahalf-cylinder, with the outside surface being smooth and rounded toperform as the journal surface, while the inside concave surface of thebody has facets that match the form, size, and angles of the multi-sidedtorque tube 720 (FIG. 7) and are the coupling or holding surface. In oneor more embodiments, the wall thickness of the cylindrical shaped body,is the distance between the outer round surface and the inner concavesurface facet-to-facet joint, and is thick enough to perform as ajournal in the simple bearing system formed between the lower bearingportion 310 and the upper bearing portion 315 for the intendedmulti-decade life span for which it is intended. For example, performingas a journal in a simple bearing for a horizontal single axis trackerwhich rotates back and forth every day for perhaps thirty years,constituting approximately twenty-two thousand wipes. The wall thicknessis also sufficient enough to transfer the torque from one torque tube720 to the next torque tube 720.

In one or more embodiments, the outside round/circular bearing surfacemaximizes the surface contact to the bearing to minimize pressure at thebearing interfaces, and therefore minimizing wear on journal-coupler andthe bearing, and therefore performing as the journal in a simple bearingsystem.

In some embodiments, the two flanges on opposite sides of the body ofeach of the first portion 110 and the second portion 120 serve themultiple purposes of clamping the two halves of the journal-couplertogether, therefore coupling and holding in place the two end-to-endtorque tubes 720 (see, e.g., FIGS. 7B, 8B, 9B, 10B, 11B and 12B) fortransferring the torque from one torque tube 720 to the next torque tube720, and of abutting against the shoulders of the mounting plate of thesimple bearing formed between the upper bearing portion 315 and thelower bearing portion 310) to help stop and support the torque tubes 720at their intended limits of rotation in both a clockwise andcounter-clockwise direction (e.g., when driven by, for example, a motorfor rotating the torque tubes 720).

FIG. 3A shows a front view of the first portion 110 of thecoupler-journal being placed into the lower bearing portion 310,according to some embodiments. FIG. 3B shows a side view of the firstportion 110 of the coupler-journal being placed into the lower bearingportion 310, according to some embodiments. As shown, the first portion110 of a coupler-journal half with its faceted concave inner surfacefacing up being lowered in the direction of the arrow into thesemi-circular bearing surface of the lower bearing portion 310. In oneor more embodiments, the round outer surface of the body of the firstportion 110 of the coupler-journal mates with, sits and rotates againstthe round bearing surface of the lower bearing portion 310.

FIG. 4 shows a perspective view of the first portion 110 of thecoupler-journal placement into the lower bearing portion 310, accordingto some embodiments. In some embodiments, the upright prongs 311 and 312of the lower bearing portion 310 pass through (following the path of thedashed lines) the first opening 111 and the second opening 112 in thetwo flanges of the first portion 110 of the coupler-journal.

FIG. 5A shows a top view of the first portion 110 of the coupler-journalcoupled with the lower bearing portion 310, according to someembodiments. As shown, the upright prongs 311 and 312 can be seen fromthe respective first opening 111 and the second opening 112.

FIG. 5B shows a front view of the first portion 110 of thecoupler-journal coupled with the lower bearing portion 310, according tosome embodiments. FIG. 5C shows a side view of the first portion 110 ofthe coupler-journal coupled with the lower bearing portion 310,according to some embodiments. As shown, the first portion 110 of thecoupler-journal, with its faceted concave interior surface facing up, isresting on the bearing surface of the lower bearing portion 310. In oneexample embodiment, when the flanges of the first portion 110 ishorizontal or parallel with a surface (e.g., the ground surface), theupright prongs 311 and 312 are sized to both be equal with, lower thanor above the first opening 111 and the second opening 112. When thefirst portion 110 of the journal-coupler is rotated (e.g., clockwise orcounter-clockwise), the upright prongs 311 and 312 remain in a fixedorientation and either pass above or below the respective first opening111 and the second opening 112 depending on the amount of rotation ofthe first portion 110.

FIG. 6 shows a perspective view of the first portion 110 of thecoupler-journal coupled with the lower bearing portion 310, according tosome embodiments. As shown, the lower portion 110 is rotated clockwisesuch that the upright prong 311 is oriented below the first opening 111and the upright prong 312 is oriented above the second opening 112.

FIG. 7A shows a front view of a torque tube 720 being placed into thefirst portion 110 of the coupler-journal that is connected with thelower bearing portion 310, according to some embodiments. FIG. 7B showsa side view of the torque tube 720 being placed into the first portion110 of the coupler-journal that is connected with the lower bearingportion 310, according to some embodiments. As shown in FIG. 7B, thereare two end-to-end torque tubes 720 being lowered (in the direction ofthe arrows) into the faceted concave surface of the first portion 110 ofthe coupler-journal. In one example, the torque tubes 720 may bemanually lowered into the first portion 110 by hand, by a liftingdevice, etc.

FIG. 8A shows a front view of the torque tube 720 connected with thefirst portion 110 of the coupler-journal that is connected with thelower bearing portion 310, according to some embodiments. FIG. 8B showsa side view of the torque tubes 720 connected with the first portion 110of the coupler-journal that is connected with the lower bearing portion310, according to some embodiments. In one or more embodiments, thetorque tubes 720 are placed (flush) within the interior portion of thefirst portion 110 and are sized together with the first portion 110 (andthe second portion 120) in order for rotation of the first portion 110(and the second portion 120) to avoid unnecessary lateral movement ofthe torque tubes 720 when mounted within the first portion 110 and thesecond portion 120.

FIG. 9A shows a front view of the second portion 120 of thecoupler-journal being placed over the torque tubes 720 that are placedwithin the first portion 110 of the coupler-journal that is connectedwith the lower bearing portion 310, according to some embodiments. FIG.9B shows a side view of the second portion 120 of the coupler-journalbeing placed over the torque tubes 720 that are placed within the firstportion 110 of the coupler-journal that is connected with the lowerbearing portion 310, according to some embodiments. The faceted concavesurfaces of the first portion 110 and the second portion 120 are inalignment with the faceted surfaces of the torque tubes 720 to providenon-slip rotation of the torque tubes 720.

FIG. 10A shows a front view of the second portion 120 of thecoupler-journal securely connected with the first portion 110 of thecoupler-journal with the torque tubes 720 placed between the firstportion 110 and the second portion 120 of the coupler-journal, and thefirst portion 110 of the journal-coupler is connected with the lowerbearing portion 310, according to some embodiments. FIG. 10B shows aside view of the second portion 120 of the coupler-journal securelyconnected with the first portion 110 of the coupler-journal with thetorque tubes 720 placed between the first portion 110 and the secondportion 120 of the coupler-journal, and the first portion 110 of thejournal-coupler is connected with the lower bearing portion 310,according to some embodiments. In some embodiments, the first portion110 and the second portion 120 of the coupler-journal are fastenedtogether (e.g., with bolt/washer/nut hardware, etc.) clamping in placethe two end-to-end torque tubes 720. The fastening of the two torquetubes 720 provides for transferring the torque from one torque tube 720to the adjoining torque tube 720, which couples together the two torquetubes 720 for simultaneous rotation when a force is applied to one ofthe torque tubes 720. The two coupler-journal halves (first portion 110and the second portion 120) form a fully round and cylindrical journalthat rests and rotates inside a smooth (e.g., and round, etc.) bearingsurface of the lower bearing portion 310.

FIG. 11A shows a front view of an upper bearing portion 315 being placedover the second portion 120 of the coupler-journal (in the direction ofthe arrows) that is securely connected with the first portion 110 of thecoupler-journal with the torque tubes 720 placed between the firstportion 110 and the second portion 120 of the coupler-journal, and thefirst portion 110 of the journal-coupler is connected with the lowerbearing portion 310, according to some embodiments. FIG. 11B shows aside view of an upper bearing portion 315 being placed over the secondportion 120 of the coupler-journal that is securely connected with thefirst portion 110 of the coupler-journal with the torque tubes 720placed between the first portion 110 and the second portion 120 of thecoupler-journal, and the first portion 110 of the journal-coupler isconnected with the lower bearing portion 310, according to someembodiments. In one or more embodiments, the upper bearing portion 315is manually lowered onto the lower bearing portion 310 at the intendedinterface points on the ends of the two upward (pointing) prongs 311 and312 (see, e.g., FIGS. 4, 15) of the lower bearing portion 310.

In some embodiments, the lower bearing portion 310 and the upper bearingportion 315 form a bearing housing to hold a rotating journal beingcomposed of the first portion 110 and the second portion 120 thatlatch/fasten together for assembly and disassembly. In one embodiment,not placing any tension or shear force of the fasteners 210 hardwarethat keeps the two bearing housing components (the upper bearing portion315 and the lower bearing portion 310) in alignment. One or moreembodiments include the bearing lower portion 310 and the upper bearingportion 315 which when latched together (e.g., fastened, bolted,screwed, etc.) form a bearing housing to hold and maintain a journal forthe torque tubes 720 onto which solar panels are mounted.

In some embodiments, the wall thicknesses of the lower bearing portion310 and the upper bearing portion 315 are thick enough to perform as abearing race in a simple bearing system for the multi-decade life forwhich it is intended (e.g., performing as a simple bearing for a singleaxis tracker which will rotate back and forth daily for thirty years,constituting approximately twenty-two thousand turns). The wallthickness is also sufficient enough to hold the journal and hence thetorque tubes 720 and solar panels in place when subjected to gravityforces and wind forces.

In one or more embodiments, the round bearing surface formed by thelower bearing portion 310 and the upper bearing portion 315 maximizesthe surface contact to the journal-coupler to minimize pressure at thesimple bearing interfaces, and to minimize wear on the embodiments.

FIG. 12A shows a front view of the upper bearing portion 315 securelyconnected to the lower bearing portion 310, where the second portion 120of the coupler-journal is securely connected with the first portion 110of the coupler-journal with the torque tubes 720 placed between thefirst portion 110 and the second portion 120 of the coupler-journal, andthe first portion 110 of the coupler-journal is connected with the lowerbearing portion 310, according to some embodiments. FIG. 12B shows aside view of the upper bearing portion 315 securely connected to thelower bearing portion 310, where the second portion 120 of thecoupler-journal is securely connected with the first portion 110 of thecoupler-journal with the torque tubes 720 placed between the firstportion 110 and the second portion 120 of the coupler-journal, and thefirst portion 110 of the coupler-journal is connected with the lowerbearing portion 310, according to some embodiments.

In some embodiments, the upper bearing portion 315 attached to the lowerbearing portion 310 forms a fully circular bearing with a 360° round,smooth, and simple bearing surface. The formed bearing guides andretains the coupler-journal and hence the torque tubes 720, forming asimple bearing. The simple bearing sustains loads from gravity, wind,and seismic forces that act on the torque tubes 720, both as adirectional force and as a torsional force. In some embodiments, thesimple bearing also forms an electrical ground path between the formedbearing and the coupler-journal via constant metal to metal contact andunder continuous interface pressure of which undergoes dailysurface-to-surface interface wiping from the two approximateninety-degree rotations (90 degree turning during sun tracking andback-tracking, and 90 degree return turn) per day.

FIG. 13 shows a perspective isolated view of the lower bearing portion310, according to some embodiments. The lower bearing portion 310includes the upright prongs 311 and 312, pier insert stops 313 and 314,pier insert portion 316 and fastening slots 317. The bearing surfaceforms a smooth semi-circle. The upright prongs 311 and 312 terminatewith the latching portions 320 and 322 including through-holes to house,for example, fasteners, bolts/screws/etc., that captures the upperbearing portion 315.

FIG. 14A shows a front perspective isolated view of the upper bearingportion 315, according to some embodiments. The bearing surface 319forms a smooth semi-circle. The two protruding flat flanges 321 and 323at the bottom of the two ends of the upper bearing portion 315 aredesigned to slide into a capture feature of the latching portions 320and 322 (FIG. 13) of the lower bearing portion 310. In one or moreembodiments, a gusset 325 (FIG. 14B) is added to flange 321, and agusset 324 (FIG. 14B) is added (e.g., welded, formed/molded, fastened(e.g., screws, bolts, etc.)) to flange 323 to give additional strengthto the flanges 321 and 323 when a pull force is applied to the upperbearing portion 315. Only one gusset is attached per side to allow thebearing upper portion 315 to slide sideways into the latching portions320 and 322 of the lower bearing portion 310.

FIG. 14B shows a rear perspective isolated view of the upper bearingportion 315, according to some embodiments. The gussets 324 and 235 helphold the two flanges 321 and 323 in place.

FIG. 15 shows a combined perspective view of the upper bearing portion315 and the lower bearing portion 310, according to some embodiments. Asshown, the upper bearing portion 315 and the lower bearing portion 310are in a near-ready attachment position. The upper bearing portion 315is lowered to the lower bearing portion 310 so that the two flanges 321and 323 of the upper bearing portion 315 are just to the side of andin-line with the latching portions 320 and 322 of the lower bearingportion 310, and then moved sideways in one direction only so that thetwo flanges 321 and 323 of the upper bearing portion 315 slide into thelatching portions 322 and 320, respectively, of the lower bearingportion 310 until the sliding action is stopped by the gussets 324 and325 on the upper bearing portion 315 and the gussets 326 and 327 of thelower bearing portion 310 are positioned such that the fasteningthrough-holes of both the upper bearing portion 315 and the lowerbearing portion 310 are aligned.

FIG. 16 shows a perspective view of the coupler-journal coupled with theupper bearing portion 315 securely connected to the lower bearingportion 310 that is connected to a pier 410, according to someembodiments. The second portion 120 of the coupler-journal is securelyconnected with the first portion 110 of the coupler-journal, and thefirst portion 110 of the journal-coupler is connected with the lowerbearing portion 310. In some embodiments, the pier 410 includes an upperpier portion 413 and coupling slots 417. The upper pier portion 413 maycontact the pier insert stops 313 and 314 (FIG. 13), for example toprovide clearance for rotation movement of the coupler-journal. The pierinsert portion 316 is fastened using the coupling slots 417 aligned withfastening slots 317 using fasteners such as bolts and nuts, screws,welding, etc.

In some embodiments, the upper bearing portion 315 and the lower bearingportion 310 latch together to form one bearing housing. The latchingportions 320 and 322 (FIG. 13) of the bearing absorb all of theseparation forces for keeping the major forces off of the fasteninghardware. The bearing is a two-component (lower bearing portion 310 andthe upper bearing portion 315) system by which a torque tube 720 (see,e.g., FIGS. 7A-B-12A-B) or an axle may be lowered and quickly placedinto the lower bearing portion 310. The upper bearing portion 315 isthen quickly attached to the lower bearing portion 310. In one exampleembodiment, a fastener can then be dropped into place to aid in keepingthe latching portions 320 and 322 of the bearing in alignment and inplace. One advantage of this latching is that there is no force, eitherin shear or in tension, on the fastener (e.g., a threaded bolt and nuthardware, etc.). Another advantage of the latching bearing system isthat the mechanical parts of a single axis tracking system can be easilydisassembled and reworked if needed simply by removing the upper bearingportion 315 of the bearing housing.

References in the claims to an element in the singular is not intendedto mean “one and only” unless explicitly so stated, but rather “one ormore.” All structural and functional equivalents to the elements of theabove-described exemplary embodiment that are currently known or latercome to be known to those of ordinary skill in the art are intended tobe encompassed by the present claims. No claim element herein is to beconstrued under the provisions of pre-AIA 35 U.S.C. section 112, sixthparagraph, unless the element is expressly recited using the phrase“means for” or “step for.”

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the invention. Asused herein, the singular forms “a”, “an” and “the” are intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. It will be further understood that the terms “comprises”and/or “comprising,” when used in this specification, specify thepresence of stated features, integers, steps, operations, elements,and/or components, but do not preclude the presence or addition of oneor more other features, integers, steps, operations, elements,components, and/or groups thereof.

The corresponding structures, materials, acts, and equivalents of allmeans or step plus function elements in the claims below are intended toinclude any structure, material, or act for performing the function incombination with other claimed elements as specifically claimed. Thedescription of the embodiments has been presented for purposes ofillustration and description, but is not intended to be exhaustive orlimited to the embodiments in the form disclosed. Many modifications andvariations will be apparent to those of ordinary skill in the artwithout departing from the scope and spirit of the invention.

Though the embodiments have been described with reference to certainversions thereof; however, other versions are possible. Therefore, thespirit and scope of the appended claims should not be limited to thedescription of the preferred versions contained herein.

What is claimed is:
 1. A journal-coupler comprising: a first portionincluding a first pair of flanges and a first coupler portion; and asecond portion removably coupled to the first portion, the secondportion including a second pair of flanges and a second coupler portion;wherein the first coupler portion and the second coupler portion combineto form an enclosed torque tube portion.
 2. The journal-coupler of claim1, further comprising: an upper bearing portion; and a lower bearingportion removably coupled to the upper bearing portion; wherein theupper bearing portion combined with the lower bearing portion form abearing enclosure.
 3. The journal-coupler of claim 2, wherein the firstportion comprises a first opening and a second opening, and the secondportion comprises a third opening and a fourth opening.
 4. Thejournal-coupler of claim 3, wherein the first portion includes a firstsemi-circular exterior portion, the second portion includes a secondsemi-circular exterior portion, and the first semi-circular exteriorportion and the second semi-circular exterior portion combine forenclosure by the bearing enclosure.
 5. The journal-coupler of claim 3,wherein the lower bearing portion comprises: a pier insert portionincluding fastening slots; a first prong including a first latchingportion; and a second prong including a second latching portion.
 6. Thejournal-coupler of claim 5, wherein: the lower bearing portion furthercomprises a pair of stop portions; and the upper bearing portioncomprises a pair of gussets.
 7. The journal-coupler of claim 5, wherein:the combined first portion and the second portion is configured torotate within the bearing enclosure; and the first pair of flanges andthe second pair of flanges each comprise a plurality of fasteningthrough-holes configured for receiving fasteners that couple the firstportion with the second portion.
 8. The journal-coupler of claim 7,wherein: the first opening and the third opening align to form a firstwindow; the second opening and the fourth opening align to form a secondwindow; the lower bearing portion and the upper bearing portion coupletogether through the first window and the second window; the pier insertportion is configured for attachment with a pier; and the enclosedtorque tube portion is configured to couple with a first torque tube anda second torque tube.
 9. A journal-coupler system comprising: a firstportion including a first pair of flanges and a first coupler portion; asecond portion removably coupled to the first portion, the secondportion including a second pair of flanges and a second coupler portion;an upper bearing portion; and a lower bearing portion removably coupledto the upper bearing portion; wherein the upper bearing portion and thelower bearing portion combine to form a bearing enclosure for the firstportion and the second portion.
 10. The journal-coupler system of claim9, wherein: the first coupler portion and the second coupler portioncombine to form an enclosed torque tube portion; the first portioncomprises a first opening and a second opening; and the second portioncomprises a third opening and a fourth opening.
 11. The journal-couplersystem of claim 10, wherein: the first portion includes a firstsemi-circular exterior portion; the second portion includes a secondsemi-circular exterior portion; and the first semi-circular exteriorportion and the second semi-circular exterior portion combine forenclosure by the bearing enclosure.
 12. The journal-coupler system ofclaim 10, wherein the lower bearing portion comprises: a pier insertportion including fastening slots; a first prong including a firstlatching portion; and a second prong including a second latchingportion.
 13. The journal-coupler system of claim 12, wherein: the lowerbearing portion further comprises a pair of stop portions; and the upperbearing portion comprises a pair of gussets.
 14. The journal-couplersystem of claim 12, wherein: the combined first portion and the secondportion is configured to rotate within the bearing enclosure; and thefirst pair of flanges and the second pair of flanges each comprise aplurality of fastening through-holes configured for receiving fastenersthat couple the first portion with the second portion.
 15. Thejournal-coupler system of claim 14, wherein: the first opening and thethird opening align to form a first window; the second opening and thefourth opening align to form a second window; the lower bearing portionand the upper bearing portion couple together through the first windowand the second window; the pier insert portion is configured forattachment with a pier; and the enclosed torque tube portion isconfigured to couple with a first torque tube and a second torque tube.16. A system for solar panel tracking, the system comprising: ajournal-coupler including: a first portion including a first pair offlanges and a first coupler portion; and a second portion removablycoupled to the first portion, the second portion including a second pairof flanges and a second coupler portion; a bearing enclosure including:an upper bearing portion; and a lower bearing portion removably coupledto the upper bearing portion; and a first torque tube and a secondtorque tube each configured for coupling with one or more solar panels;wherein the upper bearing portion and the lower bearing portion combineto form a bearing enclosure for the journal-coupler.
 17. The system ofclaim 16, wherein: the first coupler portion and the second couplerportion combine to form an enclosed torque tube portion that receives aportion of the first torque tube and portion of the second torque tube;the first portion comprises a first opening and a second opening; andthe second portion comprises a third opening and a fourth opening. 18.The system of claim 17, wherein: the first portion includes a firstsemi-circular exterior portion; the second portion includes a secondsemi-circular exterior portion; the first semi-circular exterior portionand the second semi-circular exterior portion combine for enclosure bythe bearing enclosure; and the lower bearing portion comprises: a pierinsert portion including fastening slots; a first prong including afirst latching portion; and a second prong including a second latchingportion.
 19. The system of claim 18, wherein: the lower bearing portionfurther comprises a pair of stop portions; the upper bearing portioncomprises a pair of gussets; the journal-coupler is configured to rotatewithin the bearing enclosure; and the first pair of flanges and thesecond pair of flanges each comprise a plurality of fasteningthrough-holes configured for receiving fasteners that couple the firstportion with the second portion.
 20. The system of claim 19, wherein:the first opening and the third opening align to form a first window;the second opening and the fourth opening align to form a second window;the lower bearing portion and the upper bearing portion couple togetherthrough the first window and the second window; and the pier insertportion is configured for attachment with a pier.